Building a Digital Platform to Solve Inbound Logistics Challenges
HSSMI worked with a British OEM, specialised in electric vehicle manufacture, that was looking to launch a new product. HSSMI designed a bespoke and customisable digital solution, which helped the OEM tackle challenges related to inbound process standardisation and control, visibility and traceability of stock, and delivery planning and scheduling.
Using Simulation to Plan New Product Introduction
HSSMI used simulation tools to model the body assembly area at LEVC, in order to develop and optimise flow parts and minimise disruption of the ongoing production of the TX5 (Taxi). Many vital decisions needed to be made for the area, such as what investment is needed, where stations should be placed, and when and how parts should feed into the system.
Manufacturing Layout Assessment and Optimisation for New Product Introduction
HSSMI supported LEVC in the introduction of the new VN5 vehicle. The HSSMI team used its expertise in productivity improvement and scale-up, to support the introduction of the new product. The focus was on the critical workstations that would have the most impact.
Assessing Warehouse Requirements Through Manufacturing Simulation to Support Strategic Decision-Making
HSSMI supported LEVC in the introduction of the new VN5 vehicle. The HSSMI team used advanced manufacturing simulation tools to model the warehouse area in order to assess requirements for new equipment and facilities, configure and optimize part flows, assess warehouse requirements, and plan for the effects these changes will have across the plant, in areas such as logistics
Creating a Closed Loop Supply Chain for 3D Printing Filaments
HSSMI worked in a collaborative research project called Closed Loop Innovation in Fused Filament Fabrication (CLIFFF) with In-Cycle and GoPrint3D. The project aimed to take 3D printed waste, such as failed or discarded prints, and convert it into high value recycled filaments.
Conducting a Life Cycle Assessment to Limit Waste and Improve Packaging
HSSMI helped an automotive OEM assess the environmental benefits of changing their packaging strategy from expendable packaging (cardboard) to returnable packaging. HSSMI’s expertise in circular economy and life cycle assessment (LCA) guided the OEM to become more sustainable.
Repurposing Strategy for the Transition from Internal Combustion Engines to Electric Powertrains
As part of the E:PriME project, HSSMI has been helping Ford Motor Company assess its ability to repurpose the facilities, that until now have been used for the production of internal combustion engines, for the manufacture of electric powertrains. This work resulted in a comparative analysis between ICE and E- Motor component manufacturing processes.
Cobot Implementation on Shop Floor for Ford Motor Company
Ford Motor Company (FMC) aimed to use collaborative robots (cobots) for quality checking engine wiring harnesses at its Dagenham engine plant. HSSMI has developed the Risk Assessment for Collaborative Environment (RACE) tool that can virtually assess risks to operators in a workstation. With their knowledge and experience in cobots, HSSMI was able to support FMC to implement the cobot systems on their shop floor.
Driving Packaging Improvements and Cost Savings at a UK Automotive OEM
HSSMI helped an automotive OEM to obtain full packaging control, increase packaging quality, prove supply chain savings and reduce environmental impact. HSSMI’s expertise in packaging design and engineering guided the OEM to completely reassess their suppliers’ packaging and integrate new packaging solutions, in addition to becoming more sustainable.
Future Market Study for JW Froehlich UK Ltd
JW Froehlich UK Ltd have supported the automotive industry throughout their 40 years, producing leak tests, engine hot and cold tests and other machine technologies. JW Froehlich UK Ltd have constantly evolved their offering and are now looking to maximise the opportunity of being at the centre of change following automotive powertrain electrification.
Cobot Design and Certification (CDC) for Ford Motor Company
Ford Motor company, specifically their Dagenham facility, aims to introduce an automatic checking system using collaborative robots for quality checking of electrical harnesses. As a part of the Cobot Design and Certification (CDC) service, HSSMI provided a project, with a set of defined deliverables, to assess the suitability of collaborative robots for this application.
Virtual Reality Support for Ford Motor Company
Ford Motor Company announced that they were looking to introduce the use of Virtual Reality (VR) into the manufacturing side of their business, on a trial basis, in order to understand the benefits of adopting this technology into their wider organisation. HSSMI therefore provided a short-term project with a set of defined deliverables to enhance the experience of using VR.
Risk Assessment for Collaborative Environments
Risk Assessment for Collaborative Environments (RACE) is a feasibility study which envisioned the development of a simulation tool to perform virtual risk assessments of collaborative applications. Using inputs such as the robot’s program and/or task, the operator’s task and CAD models of the workstation and the production facility, a simulation is performed to identify any risk of collision between the robot and the operator.
Industrial Ergonomic and Assembly Analysis with Optimisation for CNH Industrial
CNH Industrial hoped to create a template for the enhanced, sustainable deployment of advanced lean techniques within a ‘New Assembly Line Standard’. Specific assistance was sought from HSSMI within Automation, Process Planning and Ergonomics such that these could be utilised as a standard for future CNH Industrial assembly line installations.
Occupancy Study for Loughborough University London
Loughborough University London (LUL), located on the Queen Elizabeth Olympic Park in East London, has experienced a surge in postgraduate students attending the campus to study. Due to the running cost of a workstation and the opportunity to maximise the utilisation of space, the university intends to use a system where they can monitor the behavioural patterns for the utilisation of the workstations and meeting rooms.
Material Flow Simulation for Ford Motor Company
Material Flow Simulation was a commercial project which established the current state of the material flow for the trim line at the Ford Valencia plant through the generation of a simulation model.
Virtual Reality for Factory Cell Comparison for AGM Batteries
Virtual Reality (VR) for Factory Cell Comparison is a project which envisioned the generation of a virtual reality environment to facilitate the comparison of a newly designed battery cell, incorporating RF technology against a traditional battery cell design.
SME Productivity Improvement for Instant Spaces
Instant Spaces is looking to mass produce structural and insulated building panels, upscaling the batch operation they currently perform at their London site. HSSMI developed a project with a defined scope of works and deliverables, to support Instant Spaces with their long-term vision of mass production. HSSMI delivered an on-site process mapping exercise detailing the current state followed by the development of a future state process map.
Augmented Manufacturing Reality
The Augmented Manufacturing Reality project (AMReality) involved the creation of an integrated virtual and physical manufacturing environment overlaid with digital data (e.g. CAD, simulations, video etc.) alongside information about the physical environment (e.g. size, temperature, power usage etc.)
Electric Vehicle Powertrain School
Electric Vehicle Powertrain School (EVPS) is an advanced-level, technical boot camp designed to teach delegates how to design for manufacture, build and run production of the different primary elements of an electric vehicle’s (EV’s) powertrain. The EV industry is due to grow exponentially and it’s vital that those involved in automotive manufacturing, and its surrounding industries keep their technical knowledge up-to-date to remain at the forefront of the industry.
CoBot Design & Certification
The Cobot Design and Certification (CDC) service is a unique offering which assesses the feasibility of implementing truly collaborative applications in an industrial environment, by using virtual design and simulation. Establishing the suitability of collaborative applications before making significant investment ensures that the end solution is fit for purpose and meets current standards.
Circular Economy Maturity Assessment
Change the way your business makes, uses and discards products with the HSSMI Circular Economy Maturity Assessment (CEMA). Based on circular economy principles, the CEMA evaluates your business’s current state of circular economy and helps define, shape and direct your business’s journey towards its ideal state of circularity.
Digital Readiness Review
Digital Readiness Review is a comprehensive and strategic workshop, delivered by experienced HSSMI consultants, to assess your organisation’s current and desired digital future state. Through the expert advice and facilitation of our consultants, we will work closely with your organisation to understand your business goals and objectives, before developing a strategy to reach them.
Developing Interactive Virtual Reality Environments
Our team of skilled visualisation engineers have combined their shop floor knowledge with the latest advancements in the world of Virtual Reality (VR), creating computer-generated immersive simulations that can be explored and interacted with by people across all areas of the business using a Head Mounted Display (HMD).
HySMART will explore the feasibility of implementing advanced robotics processes to enable scale up in the manufacture of hydrogen fuel cell stack products. It is expected that the results of this feasibility study will increase confidence in hydrogen fuel cell technology and accelerate commercial uptake in the automotive sector by identifying ways to reduce costs and improve conformability, quality and robustness of the end product.
Li-BAR is a six-month study to determine the feasibility of establishing co-located battery pack assembly and remanufacturing facilities. Co-locating the sites will provide opportunities to optimally use batteries throughout their lives, maximise value leveraged from components through reuse, minimise operational and capital costs, and reduce waste.
CLiCCC will evaluate the economic viability of extracting lithium from decomposed granite, which is also rich in kaolin and abundantly present in Cornwall. Extracting both lithium and kaolin from the same source rock will increase the competitiveness of kaolin on the global market while establishing a steady domestic supply of lithium.
AcouBat will test a novel acoustic battery testing method in a practical setting – on AMTE Power’s cell manufacturing line. Alongside the physical validation, a digital simulation of the testing facility will be created by HSSMI to determine where on the production line the acoustic testing method could bring the most benefit.
In Thurso+, HSSMI is working together with AMTE Power to explore ways of increasing the productivity of AMTE Power’s existing cell manufacturing facility and develop a plan to transition to a high-volume plant. The project will explore how AMTE Power’s facility could best adopt the innovative methodologies, procedures and equipment used in state-of-the-art Gigafactories outside of the UK.
CO-VERSATILE is a pan-European project to deploy concepts for repurposing and scaling up flexible and sustainable production methods and supply chain solutions to rapidly address Europe’s demand for essential medical equipment and supplies. CO-VERSATILE project members will leverage their expertise and network to repurpose existing technologies and services for elevating the adaptability and resilience of the manufacturing sector.
5GEM-UK aims to demonstrate the value that 5G will bring to the manufacturing industry by creating testbeds at Ford and TWI, which will enhance shop floor monitoring – from enabling real-time monitoring and control of machines and processes to improving data collection. As part of the project, HSSMI will develop new productivity enhancing digital tools and applications.
The ReGaIL project seeks to develop a recovery process for gallium from bulk sourced end-of-life LED products. The recovered gallium can then be used in a compound of gallium nitride (GaN) as a semiconductor in power electronics, machines, and drives (PEMD). The recovery process flow will be tested and validated via a discrete event simulation, designed by HSSMI.
PET Full Loop
PET Full Loop seeks to improve the state of recycling in the UK by developing the country’s first dual PET bottle and tray recycling facility. HSSMI will leverage its expertise in applying digital tools in various industries to create a digital twin of the recycling facility. This is understood to be a novel approach for the waste industry.
Perseus aims to develop UK expertise in equipment and tooling needs through the development of a flexible ICE/EDU manufacture strategy. Simulation tools and flexible facility design will enable the consortium to explore scenarios linked to changes in volume, layout, cycle times, component design and operations. The project will also create dedicated training courses to upskill UK engineers in EDU manufacture.
The aim of the Electrified Powertrain Pilot Line for Manufacturing Engineering (E:PriME) project is to create unique capabilities for ultra-high-volume manufacture of next generation powertrains. The consortium consists of the manufacturing engineering and machine tool builder supply chain of these new powertrains with the aim to develop new processes and test them at rate whilst integrating new manufacturing concepts based on Industry 4.0.
Project LEWAS will identify viable and cost-effective methods for improving fuel efficiency of aquaculture workboats and contribute to decreasing their greenhouse gas emissions by up to 25% due to decreased fuel usage, resulting in annual emission and fuel cost reductions. HSSMI will use simulation modelling to identify the methods that could bring the most economic and environmental value.
Project VALUABLE’s key objectives are to develop commercially viable metrology and test processes as well as new supply chain concepts for recycling, reuse and remanufacturing of automotive lithium-ion batteries to create a complete End-of-Life (EoL) supply chain network within the UK.
SeaTrace is a 3-month feasibility study, funded by the UK Seafood Innovation Fund’s Centre for Environment, Fisheries and Aquaculture Science, to define a traceability system for the UK’s marine by-product supply chain. SeaTrace is innovative in that it assesses the different tracking systems such as RFID, Barcode, and QR code in combination with cloud data storage architectures like blockchain technology.
The concept behind CICERO is straight-forward – tear down batteries that are at the end of first life to a modular level and re-structure them for use in a classic vehicle. HSSMI, with inputs from other partners, will create flexible battery disassembly and re-assembly processes, enabling both stations to be re-configured to perform either function as necessary.
Intelligent Naval 4.0
The IN 4.0 project aims to improve the competitiveness of naval sector companies through the adaptation of the traditional productive model towards the Industry 4.0 - guaranteeing the sector’s endurance in an increasingly demanding market where technological innovation is a key factor of strategic advantage.
An R&D project, developing advanced zero emissions hybrid technology for use within LEVC’s new zero emissions capable product range. The project will also contribute to enhancing the capabilities and sustainability of the low carbon supply chain across the UK. HSSMI is leading simulation work and the recovery & recycling strategy to capture the development of future state models to optimise manufacturing at LEVC.
Finding a second life for automotive leather in the fashion industry
A cross-industry, circular economy project, focused on capturing the full value of the leather that goes into vehicle seats. Bringing together partners from automotive, fashion and other industries, HSSMI leads the effort to investigate how leather from automotive seats could be reused in the fashion industry to create new products.
The Closed Loop Innovation for Fused Filament Fabrication (CLIFFF) project focuses on developing a new value chain from a plastic waste stream. The project is novel as it aims to develop a reverse logistics system for collecting waste from a targeted and growing 3D printing industry.
Hydrogen Diesel Injection in a Marine Environment (HyDIME) aims to make waves in the marine industry by proving the safe integration and use of hydrogen on vessels. One of HyDIME’s goals is the design and physical integration of a hydrogen injection system on a commercial passenger and vehicle ferry which will be the first of its kind worldwide. The hydrogen used in the HyDIME project will be cleanly produced from renewable energy.
High Volume Additive Manufacturing - HVAM
The overall objective of this project is to deploy High Speed Sintering technology (HSS) in a high-volume series production environment. The project aims to develop a decision-making tool that will be used to compare and contrast additive manufacturing against conventional manufacturing techniques and provide a systematic process of material selection.
Water Accelerated Technology for En-Tyre Recycling
The WATER project focused on the development of an innovative tyre recycling process which enabled the optimal recovery of high value resources from end of life car tyres. The project concentrated on the development of a novel recycling technology which used Ultra High-Pressure Water (UHPW) to break down and separate materials from a tyre into three distinct resources.
Hybrid Fusion Energy System
The Hybrid Fusion Energy System (HyFes) project was an initiative to fit marine vessels with batteries and allow them to operate along the River Thames in a similar way a hybrid car would. The MBNA Thames Clipper river boat service and their high-speed catamarans were chosen as a test bed, due to its stop start capabilities in operation that would suit itself to hybrid propulsion.
opendynamic Manufacturing Operating System
Opendynamic Manufacturing Operating System (openMOS) was a European project with a consortium of 15 companies which developed a modular plug-and-produce equipment. The objective of openMOS was to allow quick integration of machines and automation systems in production environments, a prerequisite for the implementation of Industry 4.0 solutions. HSSMI delivered a genetic algorithm optimiser for dynamic product routing in a manufacturing plant.
Symbiotic Simulation with Data Management
The aim of this project was to improve the speed at which simulation results of an automotive manufacturing line can be delivered by significantly reducing time to build the models and interpret the results. A discrete event simulation is a model that replicates the real world into an ordered sequence of events in digital form.
Pilot Kitting Robot - PIKBOT
This Pilot will build a robotic test cell that enables Nissan Motor Manufacturing UK to develop automated kitting capability for its part families. The cell is intended to be modular and scalable built on low cost, commercially available hardware integrated together with advanced software capability.
Holistic Immersive Collaboration
The project creates an environment for holistic immersive collaboration i.e. connecting multiple visualisation options to a central, company-wide digital knowledge pool. The objective of the project is to shorten the time to ramp up automotive manufacturing and reduce time to market whilst decreasing the cost of machine maintenance. The focus of the project is to develop number of augmented and virtual reality technologies along with a platform.
FactorySym project is an analysis of the workflows used to create Digital Twins, focusing on breaking the concepts down into parts, and using interchangeable software packages, rather than complete all-in-one solutions. The consortium included an automotive manufacturer, and simulation and IoT solutions providers. The aim is to make Digital Twin technologies more accessible to manufacturers, and integrate with existing systems, not replace them.
The 'Manufacturing Gamification’ project proved that through the adoption of appropriate gamification techniques, employee engagement and productivity improved without compromising assembly quality. The project was a first for the implementation of the connection between gaming methods and the automotive industry.